CN119098576A - Casting machine and casting method - Google Patents
Casting machine and casting method Download PDFInfo
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- CN119098576A CN119098576A CN202410739647.XA CN202410739647A CN119098576A CN 119098576 A CN119098576 A CN 119098576A CN 202410739647 A CN202410739647 A CN 202410739647A CN 119098576 A CN119098576 A CN 119098576A
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
- B22D23/006—Casting by filling the mould through rotation of the mould together with a molten metal holding recipient, about a common axis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/08—Shaking, vibrating, or turning of moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D35/00—Equipment for conveying molten metal into beds or moulds
- B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D37/00—Controlling or regulating the pouring of molten metal from a casting melt-holding vessel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/04—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like tiltable
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/06—Equipment for tilting
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
Abstract
本发明涉及一种铸造机和一种用于将熔体浇注到铸模中的方法,其中至少一个铸模(43)容纳在铸造机的框架上,其中铸模通过铸造机的枢转装置在将熔体注入到铸模中时移动并围绕轴线(52)倾斜,其中,通过铸造机的传感器装置在将熔体注入到浇口(48)中时检测熔体在浇口中和/或在铸模的浇道(50)中的液位。
The invention relates to a casting machine and a method for pouring a melt into a casting mold, wherein at least one casting mold (43) is accommodated on a frame of the casting machine, wherein the casting mold is moved and tilted about an axis (52) by a pivot device of the casting machine when the melt is poured into the casting mold, and wherein the liquid level of the melt in the pouring gate (48) and/or in the runner (50) of the casting mold is detected by a sensor device of the casting machine when the melt is poured into the pouring gate (48).
Description
Technical Field
The invention relates to a casting machine and a method for pouring a melt into casting moulds, wherein at least one casting mould is accommodated on a carrier of the casting machine, wherein the casting mould is moved by a pivoting device of the casting machine when the melt is filled into the casting mould and is tilted about an axis.
Background
Such casting machines and methods are well known in the art, wherein liquid metal is always filled into the mould during casting until the mould or the cavity of the mould is completely filled. After solidification of the melt, the subsequently formed component may be shaped or removed from the mold. The casting mold may be a permanent mold or a disposable mold, such as a permanent mold or a sand mold. Importantly, when the melt is filled into the mold (which can be accomplished by the crucible), the mold moves or tilts about the axis. For this purpose, the casting mould is arranged on a movable support of the casting machine. The support of the casting machine is designed such that the casting mould can be moved by a pivoting device or tilted about an axis. By tilting the mould when pouring the melt, the mould can be completely filled with metal according to the shape of the cavity in the mould without defects such as air pockets, cold flow etc. forming in the mould. It is also advantageous if the melt poured into the mould fills the mould cavity uniformly and is not randomly distributed in the mould cavity. This also ensures a controlled filling process of the melt. Overall, high quality cast metal products can be obtained with little waste.
However, as has been shown, when the melt is poured into a mold, there arises a problem that the melt for casting is excessive and melt overflow occurs at the gate of the mold. In principle, too little melt should not be poured into the mould, otherwise the cast product will have defects. Thus, the melt quantity is metered in such a way that the melt quantity is sufficiently large. However, the spilled melt requires constant, repeated cleaning of the casting equipment, may cause damage to the casting machine, and requires the energy required for melting, which can be saved.
Disclosure of Invention
It is therefore an object of the present invention to propose a method for pouring a melt into a casting mould and a casting machine which enable improved filling of the casting mould and reduced costs.
The object is achieved by a method having the features of claim 1 and a casting machine having the features of claim 16.
In the method according to the invention for pouring a melt into a casting mould, at least one casting mould is accommodated on a carrier of a casting machine, wherein the casting mould is moved by a pivoting device of the casting machine when pouring the melt into the casting mould and is tilted about an axis, wherein a level of the melt in the gate and/or in a runner of the casting mould is detected by a sensor device of the casting machine when pouring the melt into the gate.
In the method according to the invention, it is provided that the casting machine tilts or pivots the casting mould about at least one axis when pouring the melt into the casting mould, i.e. during the casting process. The metal or melt flowing into the mould can thereby continuously fill the mould without causing uncontrolled filling of the mould cavity in the mould, in which case the melt subsequently fills the mould cavity with a random melt flow. In order to prevent the melt from flowing out of the casting mold during the injection of the melt, the tilting of the casting mold can be accelerated during the filling process to such an extent that this is substantially excluded during the filling period. However, this results in a random distribution of the melt in the mold cavity, thereby promoting the formation of casting defects and oxide inclusions. By means of the sensor device of the casting machine, the level of the melt in the gate and/or in the runner of the casting mold is now detected when the melt is poured into the gate of the casting mold. Sensor means may thereby be used to determine when the level or height of the melt in the mold cavity reaches the gate or runner. Thus, the sensor device may be used to determine when there is a risk of melt spilling from the mould. The casting process can now be adjusted to prevent melt overflow. If melt is detected at the gate and/or runner of the mold, the casting process may be corrected accordingly, for example by tilting the mold about the axis and/or metering the volumetric flow of melt into the mold. In general, the filling of the mold with the melt can be optimized so that the mold does not overflow, thereby avoiding the work that would otherwise be required and saving energy. In principle, the method can be used for any type of casting mould. For example, the casting mold may be designed as a permanent mold or as a disposable mold. The casting mould is preferably a permanent mould or a sand mould. The casting mould may be designed in two or more parts.
The tilting about the axis can be controlled using a control device on the casting machine. The control means may comprise or be formed by means for data processing, for example a computer or a programmable logic controller. As part of the casting process, the control device may then manipulate, for example, a motor, actuator, or other implement, such that the mold tilts or pivots about the axis. The time course of the actuation can be stored separately in the control device of the casting mold. In particular, it may be provided that the control device performs tilting about the axis as a function of the detection of the liquid level.
Furthermore, the adjusting means of the control device can adjust the inclination about the axis during filling as a function of the liquid level as reference variable. The casting mould does not then have to be inclined continuously or at a constant speed as is known in the art, but rather is adapted dynamically to the level of the melt. It is thereby also possible to tilt the mould or to fill the cavity of the mould with melt at an optimized speed. For example, if tilting of the mould in the mould cavity during casting results in a larger volume to be filled in sections, the adjusting means may accelerate tilting of the mould and slow the tilting of the mould, for example when filling the volume, to prevent spillage. The mould may also tilt at a non-linear speed.
By means of the sensor device, the absolute position, the rotation angle and/or the rotation speed of the axis can be determined, whereby the control device can adjust the absolute position, the rotation angle or the rotation speed as a function of the liquid level as a reference variable of the previous stage. The sensor means may comprise further sensors, such as rotary encoders or other suitable sensors on the respective shafts. These sensors can then determine the actual position of the axis or the tilting angle of the mould independently of the actuation of the pivoting means for tilting the mould. The rotational speed of the shaft can also be detected by the sensor means during the movement of the mould. The control means may then also be arranged such that they output the corresponding recorded values. This may be accomplished by data transmission, digital representation, graphical representation, etc. The casting machine operator can then directly monitor the casting process. In addition, the recorded data may also be saved or recorded by the control device. The adjusting device can be designed as an adjusting system in the control device for adjusting the drive of the pivoting device such that the casting mold tilts about the axis in a desired manner during the casting process. Preferably, it can be provided that the rotation angle of the respective axis to be achieved is adjusted as a function of the end of a time section of the casting process. Since the adjustment is performed as a function of the liquid level as a reference variable of the previous stage, it is not even necessary to input values of absolute position, rotation angle and/or rotation speed into the control device, since these parameters do not necessarily have to be known by adjustment. The initial programming of the control device can therefore be dispensed with in the first place. The operation of the casting machine can thus be significantly simplified and the costs for the operator can be saved.
Using the control device, the mould can be tilted about the axis until the target level is reached. The target fluid level may then be located in the gate or runner region. The sensor device may thus also be arranged such that the liquid level to be detected is a target liquid level. This means that the sensor means can only detect when the target level is reached. On the other hand, the sensor device can also detect the absolute value of the liquid level, i.e. the rise or fall of the liquid level in the mould cavity. The sensor device then has a measuring range for the liquid level. The target liquid level may then lie within the measuring range of the sensor device. The tolerance of the target level can then also be defined in the control device.
The data about the direction of rotation, the initial rotation angle, the preferred volume flow can be transmitted separately to the control device, whereby the control device can subsequently fill the melt into the casting mold. The control device can thus be provided with a starting point or reference position for tilting about the axis. The volume flow can be defined by the rotational direction and the rotational speed. This is advantageous because the level of the melt can only be detected when the melt enters the mould.
By means of the control device, the rotational speed can be increased until the target level is reached when the mould is tilted about the axis. The rotational speed may be increased by a defined acceleration. In this way, melt overshoot can be prevented despite the detection of the liquid level. For example, the rotational speed may be continuously increased until the target level is reached, and then the rotation or tilting of the casting mold about the axis may be stopped or slowed. By increasing the rotational speed during the casting process, the casting mould or its cavity can be filled with melt particularly quickly, so that the casting process is considerably accelerated.
By means of the control device, tilting of the casting mould about the axis can be stopped when the target level is exceeded. In particular, it can be provided that the casting process is stopped when the detected liquid level exceeds the measuring range of the sensor device. The location of the target level may advantageously be selected such that the casting mould does not overflow immediately after reaching the target level. Thus, the target level may also be defined between the gate and runner of the mold.
The control device can determine the time segments until the target level is reached within a time period for filling the mold, wherein the control device shortens the time segments in the subsequent casting by increasing the melt volume for each time segment to be filled into the mold. With this control device, the casting process can be optimized to the extent that the maximum possible mold filling speed is achieved. This can be achieved by the control device continuously increasing the inclination of the mould about the axis and/or the volumetric flow rate of the melt introduced by the crucible during the continuous casting process, so that the target level is reached more quickly and thus maintained, for example, by the control device. This optimization may be performed iteratively during multiple castings of the same product.
The control means may calculate the volume of melt in the mould from the cavity, the level and the rotation angle of the shaft of the mould. For example, if the sensor means can detect the level of the melt, the control means can calculate the volume of melt that has been filled into the mould from the position of the cavity of the mould and the known volume or known shape. The control device can then derive therefrom the volume of melt which still needs to be filled into the casting mould. The control means may use knowledge of the volume of melt still to be filled to further optimise the casting process. In this way, the control device can also limit the total melt volume, so that overflow of the casting mould due to an excessively large melt volume at the end of the casting process can be avoided.
The control means may calculate the initial rotation angle based on the position of the cavity and gate of the mold on the mold. The initial rotation angle of the mold may be used as a starting point for tilting the mold about the axis prior to pouring the melt into the mold. The initial rotation angle can be selected such that the melt does not immediately come out of the gate during casting. The inclination of the casting mould or the mould cavity formed therein can thus be selected such that there is at least a gradient in the mould cavity, which allows the melt to flow into the mould cavity. The corresponding data of the mold cavity and its relative position in the mold can be stored in the control device. Depending on the position of the cavity and gate, the control device may optimally spatially position the mold at the beginning of the casting process, thereby creating an initial angle of rotation.
The control device may calculate the volume of melt that fills the mold during each time segment of filling. The melt volume or the volume flow of the melt can be determined by the rotational speed of the shaft by the control device. In principle, the control device can also calculate the total melt volume in the casting mould in the respective time segment. This is particularly advantageous if the volume of the mould cavity is known. The control device may then also determine the point in time until the casting process is completed or the period of time for pouring the melt into the mold is completed.
The control device may simulate melt flow during the filling period and output or store the simulation results. The control means may be arranged to simulate the casting process, for example using casting solidification simulation or Finite Element Method (FEM). Furthermore, simulations of the casting process that are not created by the control device may be integrated into the control device. The control device can then use this simulation to optimise the movement of the mould, for example by repeating the simulation with different parameters, to the extent that the mould cavity is filled as smoothly as possible in as short a time period as possible. This optimization may also be accomplished using artificial intelligence (KI). The control device may output the result, for example graphically, so that it can be checked and/or selected by the operator of the casting machine.
During filling, the casting mould can be tilted about a second axis by means of a pivoting device, wherein the axis is designed to extend transversely with respect to the second axis. It can thus be provided that the casting mould is tilted or rotated about an axis or a first axis and about a second axis when pouring the melt. Whereby the two axes may be designed or arranged to extend transversely with respect to each other, the mould may be moved in two planes, resulting in a movement in three dimensions during filling of the melt. This allows the movement of the mould to be adapted solely to the cavity formed in the mould during filling of the melt. Even products with complex geometries can be cast with high quality. When pouring the melt into the mould, the melt can be guided by moving the mould to a desired flow direction, which can be varied during the casting process or filling according to the shape of the product and which can be adapted to the shape of the product. Melt channels formed in the casting mold are also contemplated herein. The casting process can be designed such that the cavity of the casting mold is filled smoothly and completely, so that air inclusions and cold flow tendencies and contamination of the product by oxides are avoided. In addition, the placement of the cavity within the mold is no longer necessarily limited to the optimal location of the gate on the mold. Since the mould can be moved in two degrees of freedom, the arrangement of the mould cavity is more flexible. Depending on the shape of the product to be cast, the dimensions of the mould can be made smaller, since the arrangement of the cavities in the mould can be chosen in the most space-saving manner possible.
When the mold is tilted about an axis, the crucible filled with melt may be stationary with respect to the mold, or the crucible may be tilted about another axis. For filling the melt into the mold, a crucible containing the melt or liquid metal may be positioned at a gate in the mold. In a first embodiment of the method, it may be provided that the crucible is firmly fixed relative to the casting mold or that the crucible is moved with the movement of the casting mold in such a way that no relative movement occurs. Due to the movement of the mold, the crucible moves with it, so that the melt can be poured into the gate by this movement. According to another embodiment, the crucible may be tilted about another axis. This means that during movement of the mold when pouring the melt into the gate, the crucible can be moved relative to the mold so that more or less melt can be poured into the gate than a stationary crucible. The melt flow rate or the melt volume flow rate can thus be adjusted, for example, as a function of the shape of the mold cavity. The casting process can better adapt to the shape of the product.
The casting machine according to the invention for pouring a melt into a casting mould comprises a holder for receiving at least one casting mould and a pivoting device for moving the casting mould, wherein the casting mould is movable by the pivoting device when pouring the melt into the casting mould and is tilted about an axis, wherein the casting machine has a sensor device by means of which the level of the melt in the gate and/or in the runner of the casting mould can be detected when pouring the melt into the gate of the casting mould. Regarding the advantageous effects of the casting machine according to the invention, reference is made to the description of the advantages of the method according to the invention.
The sensor device may comprise at least one sensor, in particular an image sensor, an infrared sensor, a temperature sensor, an induction sensor, a capacitance sensor, a near field sensor, an ultrasonic sensor, a radar sensor, a magnetic sensor. In principle, the sensor may be any sensor suitable for detecting the melt level in the gate and/or runner of the mold. Furthermore, the sensor device may comprise a plurality of sensors of the same or different types. The image sensor may be constituted by, for example, an image capturing camera. The infrared sensor may be designed as an infrared diode or an infrared camera. The temperature sensor may also be formed by an infrared sensor or other means for determining temperature. The near field sensor may be formed by an inductive sensor or a capacitive sensor. A radar sensor may also be used because it is not affected by the melt temperature.
The sensor may be located remotely from, on or in the mold, preferably adjacent to or directly on the gate. It is advantageous if the sensor is not arranged directly on the mould, since the sensor is independent of the mould. For example, the sensor may be arranged and aligned on a stand of the casting machine such that it is positioned adjacent the runner, such as a camera with an optical detection range aimed at the runner. Alternatively or additionally, the sensor may also be arranged directly on the casting mold, which sensor may then be located directly at or in the gate. It is also advantageous if the sensor is arranged in the mould. This may be done, for example, by providing a recess in the mould in which the sensor is located. The sensor need not be in direct contact with the melt here, although this is also possible. For example, the position of the sensor may also be selected such that the sensor is located on the melt channel between the gate and runner of the mold.
The casting machine may comprise a casting mould and/or a crucible for filling the melt into the casting mould. The casting mold may be a permanent mold or a sand mold. The casting mould may be accommodated on a stand of the casting machine or fixed thereto such that the casting mould is movable by the pivoting means. The crucible may be arranged on the casting mould for filling the melt into the casting mould or, alternatively, may be carried along with the casting mould when the casting mould is moved during casting. This may also be done using a multi-axis robot or the like, for example. The robot may also be a component of the casting machine.
Further advantageous embodiments of the casting machine result from the characterizing features of the dependent claims related to method claim 1.
Drawings
Preferred embodiments of the present invention are explained in more detail below with reference to the accompanying drawings.
In the accompanying drawings:
fig. 1 shows a perspective view of a casting mold with an axis;
fig. 2 shows another perspective view of a casting mold with an axis;
FIG. 3 shows a side view of the casting machine;
FIG. 4 shows a rear view of the casting machine of FIG. 3;
FIG. 5 shows a partial perspective view of the casting machine of FIG. 3;
FIG. 6 is a table showing movement of the mold during casting;
FIG. 7 shows a schematic view of a mold with a crucible;
Fig. 8 shows a schematic view of a casting process of the first embodiment;
fig. 9 shows a schematic view of a casting process of the second embodiment;
FIGS. 10a-h show schematic diagrams of a method sequence for filling a casting mold according to a first embodiment;
fig. 11a-h show a schematic diagram of a method sequence for filling a casting mould according to a second embodiment.
Detailed Description
Fig. 1 shows a casting mould 10, which is formed essentially from an upper mould part 11 and a lower mould part 12, and has a gate 14 on a side 13. The mould 10 may be movable about a first axis 15 and a second axis 16 or may be tilted by a casting machine not further shown here. The first axis 15 and the second axis 16 are designed to extend horizontally with respect to the casting mould 10 and intersect at right angles at the centre of gravity 19 of the casting mould 10.
Fig. 2 shows a casting mold 10, wherein, unlike fig. 1, the casting mold 10 can be arranged on a casting machine (not shown) obliquely about a first axis 17 and a second axis 18, wherein the first axis 17 extends horizontally with respect to the casting mold 10 and the second axis 18 extends vertically with respect to the casting mold 10.
Fig. 3 to 5 schematically show a casting machine 20 having a casting mold 21 with an upper mold part 22 and a lower mold part 23. The casting machine 20 has a support 24 for receiving the casting mould 21 and a pivoting device 25 for moving the casting mould 21. By means of the pivoting means 25, the casting mould 21 can be moved at the same time as the casting of the melt into the casting mould 21 and can be tilted about a first axis 26 and a second axis 27. The first axis 26 and the second axis 27 extend horizontally and orthogonally with respect to the casting mould 21 and have a relative distance from each other. The pivot device 25 is designed with a partially circular arc-shaped frame 28 for the first axis 26, wherein the circular arc 29 of the frame 28 rests on a bearing 30 and can be moved along the bearing 30 by a drive 31. The bearing 30 is here essentially formed by two bearing rollers 32 for each frame 28, and the drive 31 is formed by an electric motor 33. For the second axis 27, the pivoting means 25 comprise a circular arc-shaped frame 34, which rests by its circular arc 35 on a bearing 36. Furthermore, a bearing pin 37 is rotatably mounted in a bearing bushing 38 of the bracket 24. The drive 39 is formed here by a hydraulic or electric drive cylinder 40, which enables the arc 35 to pivot or tilt about the second axis 27. The casting mold 21 is placed on the table 41 of the holder 24 and clamped to the table 41 by the clamping jaws 42. The position of the casting mould 21 shown here serves as a starting point for the movement of the casting mould 21 during the casting process.
Fig. 6 shows a table in which possible movements of the axes mentioned in fig. 1 to 5 during the casting process are exemplarily shown. The casting process herein extends over a period of time in which any number of steps may be performed. The step marked as start indicates the start of the time period of the casting process and the step marked as end indicates the end of the time period of the casting process. Each step is preceded by a time segment of a time period during which the melt is poured into the mold. For the first and second axes, the movement of the casting mold is performed independently of each other. For steps 1 and 2, only the first axis is initially moved, and for steps 3 and 4 both axes are moved. Starting from the starting point of the mould, the rotation angle is approximated in a specified travel time using the individual steps, resulting in the rotation speed of the individual shafts. Importantly, as the melt is poured into the mold, the mold moves about the first axis and the second axis.
Fig. 7 shows a schematic view of a casting mold 43 with a crucible 44. The mold 43 is formed of an upper mold portion 45 and a lower mold portion 46. A cavity 47 for the product to be cast is formed in the mold 43. A gate 48 is also formed on the mold 43 having a melt channel 49 that opens into a runner 50 of the cavity 47. The gate 48 is also provided with a sensor 51 by means of which the gate 48 of the casting mold 43 can monitor the level of melt in the gate 48 or in the runner 50. This may be accomplished by sensor 51 detecting the level of the melt. The casting mold 43 may be mounted obliquely about a first axis 52 and a second axis 53 on a casting machine, not shown. Crucible 44 may also be designed to be tiltable about another axis 54.
Fig. 8 shows an embodiment of a casting process of a casting mould 43 on a casting machine, wherein the casting mould 43 is tilted at an angle about a first axis 52 in the direction shown in fig. 8 during the casting process, wherein the crucible 44 is also tilted about another axis 54 in the direction shown during the casting process. The volumetric flow rate of the melt flowing into the mold 43 through the gate 48 can be increased in this manner.
In contrast, fig. 9 shows an embodiment of a casting process employing a mold 43, wherein crucible 44 is held stationary relative to mold 43 or gate 48, while mold 43 is tilted about first axis 52 in the direction shown in fig. 9. Thereby also allowing melt from crucible 44 to be poured into gate 48. The melt volume flow, which is dependent on tilting about the first axis 52, cannot be regulated by the crucible 44.
Fig. 10a to 10h schematically show a casting mould 43 with a crucible 44 during different time sections according to an embodiment of the casting process. During this casting process, the crucible 44 is always rigidly fixed or arranged without any relative movement with respect to the casting mold 43. From the starting position shown in fig. 10a, the casting mould 43 is tilted about the first axis 52 according to fig. 10b, so that the melt 55 located in the crucible 44 flows towards the gate 48. As shown in fig. 10c, the mold cavity 47 is filled with melt 55 according to an inclination about the first axis 52 until the sensor 51 located at the gate 48 detects the melt 55. The control of the casting machine, not shown here, moves the casting mould 43 and then increases the rotational speed of the casting mould 43 about the first axis 52, so that the mould cavity 47 is filled faster and the level 56 of the melt 55 in the mould cavity 47 comes outside the detection range of the sensor 51, as shown in fig. 10 e. With the continued pivoting movement according to fig. 10f, the mold cavity 47 continues to fill with melt 55, so that the liquid level 56 in the mold cavity 47 continues to rise. As shown in fig. 10g, sensor 51 again detects the level 56 of melt 55 or its gate 48. The rotational speed of the casting mold 43 about the first axis 52 is then again increased to the point where the casting mold 43 is completely filled with melt 55, as shown in fig. 10 h.
Fig. 11a to 11h show a further embodiment of a casting process using a casting mould 43 and a crucible 44, wherein the crucible 44 can be tilted about a further axis 54 in comparison with fig. 10a to 10 h. Unlike fig. 10c, the crucible 44 is now tilted relative to the casting mold 43 in the direction shown here, according to the setting of fig. 11c, so that the flow rate or volume flow of the melt 55 into the mold cavity 47 is increased. Here, too, according to fig. 11d, the melt 55 or its level 56 at the gate 48 is detected. According to fig. 11e, the rotational speed about the first axis 52 and the rotational speed of the crucible 44 about the other axis 54 are increased by a control device of the associated casting machine, which is also not shown here, to such an extent that the mould cavity 47 is rapidly filled with melt 55. As shown in fig. 11f, the cavity 47 is continuously filled until the level 56 of the melt 55 reaches the sensor 51 or the gate 48 again. By again increasing the rotational speed about the first axis 52, the cavity 47 or the mould 43 is completely filled with the melt 55, as shown in fig. 11 h.
By means of the sensor 51, the control device can control the inclination about the first axis 52 or the second axis 53 and the further axis 54 such that the inclination about the axes 52, 53, 54 is adjusted as a function of the liquid level 56 as a reference variable. The liquid level 56 may then also be a higher level reference variable, from which the absolute position, the rotation angle and/or the rotation speed are adjusted. The liquid level 56 may be defined by the control device as a target liquid level. When tilting the casting mould 43, the control means may increase the rotational speed until the target level is reached. Then, as described above, tilting of the mold 43 may be stopped or slowed such that the liquid level 56 remains substantially constant while the mold 43 or crucible 44 is tilted and the melt is poured into the mold 43. In this way, filling of the casting mould 43 can be considerably accelerated.
In principle, in the method described in fig. 1 to 11 or in the casting machine and the casting mould, it is sufficient that the casting mould is tilted about only one axis. Tilting about only one axis is therefore also included in the description of all exemplary embodiments in fig. 1-11. The movement of the casting mould 43 about the second axis is not visible in fig. 7 to 11, but may also take place. It is important that there is always a sensor that is able to detect the melt level in the gate and/or in the runner of the mold.
Claims (19)
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EP23178424.0A EP4474079A1 (en) | 2023-06-09 | 2023-06-09 | Casting machine and method for casting |
EP23178424.0 | 2023-06-09 |
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WO2010068113A1 (en) * | 2008-12-11 | 2010-06-17 | Oshaug Metall As | A method of casting metals in a mould |
AT514740B1 (en) * | 2013-05-27 | 2020-12-15 | Nemak Sab De Cv | Method and device for casting a cast part |
KR102579008B1 (en) * | 2021-08-12 | 2023-09-15 | 한국생산기술연구원 | Tilt casting apparatus that rotates in two axes |
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2023
- 2023-06-09 EP EP23178424.0A patent/EP4474079A1/en active Pending
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2024
- 2024-06-07 CN CN202410739647.XA patent/CN119098576A/en active Pending
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